Information processing system, information processing method, recording medium, node device, gateway device, manufacturing system, method of manufacturing product

ABSTRACT

An information processing system includes a plurality of node devices and a gateway device configured to communicate with the plurality of node devices. Each of the plurality of node devices is connected to a sensor configured to measure a state of a facility, and is configured to execute a measurement task. Each of the plurality of node devices is configured to add node identification information used to identify the node device and task identification information used to identify the measurement task executed by the node device, to measurement data acquired in the measurement task, and send the measurement data to the gateway device.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to an information processing system andthe like that obtains the state of a production facility by collectingmeasurement data from sensors attached to the production facility.

DESCRIPTION OF THE RELATED ART

In general, it has been difficult to find an abnormal state of aproduction facility in the maintenance of the production facility evenif the production facility is in the abnormal state, as long as theabnormal state does not hinder the operation of the production facility.For this reason, preventive maintenance that needs periodic inspection,repair, and component replacement is performed. However, the preventivemaintenance has a problem that involves the regular inspection and itsman-hours.

As countermeasures to such a problem, predictive maintenance has beentried in recent years. In the predictive maintenance, sensors aredisposed in a production facility, and the component replacement,repair, and update are performed in accordance with the state of theproduction facility for reducing unnecessary component replacement andlabor costs.

In this case, since many sensors are disposed to collect measurementdata, detailed diagnosis and early detection of abnormality can beachieved. However, if many sensors are disposed, types of the sensorsand types of measurement need to be identified in the collection ofmeasurement data.

For this reason, a diagnosis system that identifies an individual sensorand a type of measurement has already been proposed.

For example, Japanese Patent Application Publication No. 2012-238082discloses a data collection method. In the data collection method, adata collection device sends ID numbers of measuring devices and theorder of collection of measurement data, to all the measuring devices.The measuring devices are devices whose measurement data is required bythe data collection device. Each of the measuring devices determineswhether the current communication is a communication between the datacollection device and a measuring device whose ID number precedes the IDnumber of the measuring device itself, depending on the order ofcollection of measurement data; and sends the measurement data to thedata collection device at an appropriate timing.

In the conventional method, however, the data collection device has todetermine the order of collection in advance for determining the type ofmeasurement data. In addition, the data collection device has to specifymeasurement conditions, or otherwise the sensors have to send theirmeasurement conditions to the data collection device. In this case,since the measurement-condition data has to be handled in addition tothe measurement data, the amount of data will increase, possibly makingit difficult for the wireless-communication band to accommodate themeasurement-condition data and the measurement data.

Thus, it has been desired to achieve a method that can recognize ameasurement condition of a measurement data even in a limitedcommunication band.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, an informationprocessing system includes a plurality of node devices and a gatewaydevice configured to communicate with the plurality of node devices.Each of the plurality of node devices is connected to a sensorconfigured to measure a state of a facility, and is configured toexecute a measurement task. Each of the plurality of node devices isconfigured to add node identification information used to identify thenode device and task identification information used to identify themeasurement task executed by the node device, to measurement dataacquired in the measurement task, and send the measurement data to thegateway device.

According to a second aspect of the present invention, an informationprocessing method uses an information processing system. The informationprocessing system includes a plurality of node devices and a gatewaydevice configured to communicate with the plurality of node devices.Each of the plurality of node devices is connected to a sensorconfigured to measure a state of a facility, and is configured toexecute a measurement task. The method includes adding, by each of theplurality of node devices, node identification information used toidentify the node device and task identification information used toidentify the measurement task executed by the node device, tomeasurement data acquired in the measurement task, and sending themeasurement data to the gateway device.

According to a third aspect of the present invention, a node device isconnected to a sensor configured to measure a state of a facility. Thenode device is configured to execute a measurement task. The node deviceis configured to communicate with a gateway device. The node device isconfigured to add node identification information used to identify thenode device and task identification information used to identify themeasurement task executed by the node device, to measurement dataacquired in the measurement task, and send the measurement data to thegateway device.

According to a fourth aspect of the present invention, a gateway deviceis configured to communicate with a plurality of node devices. Each ofthe plurality of node devices is connected to a sensor configured tomeasure a state of a facility, and is configured to execute ameasurement task. If the gateway device receives from any one of theplurality of node devices, measurement data to which node identificationinformation used to identify the node device and task identificationinformation have been added, the gateway device stores the measurementdata to which the node identification information and the taskidentification information have been added, in a database of aninformation processing system.

According to a fifth aspect of the present invention, a manufacturingsystem includes a facility configured to manufacture a product, aplurality of node devices, each of the plurality of node devices beingconnected to a sensor configured to measure a state of the facility, andbeing configured to execute a measurement task, and a gateway deviceconfigured to communicate with the plurality of node devices. Each ofthe plurality of node devices is configured to add node identificationinformation used to identify the node device and task identificationinformation used to identify the measurement task executed by the nodedevice, to measurement data acquired in the measurement task, and sendthe measurement data to the gateway device.

Further features of the present invention will become apparent from thefollowing description of exemplary embodiments with reference to theattached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an information processing system of anembodiment.

FIG. 2 is a block configuration diagram of a node device of theembodiment.

FIG. 3 is a block configuration diagram of a gateway device of theembodiment.

FIG. 4 is a task table of the node device of the embodiment.

FIG. 5 is an index table of the gateway device of the embodiment.

FIG. 6 is a flowchart illustrating an operating procedure of the nodedevice of the embodiment.

FIG. 7 is a flowchart illustrating an operating procedure of the gatewaydevice of the embodiment.

FIG. 8 is a schematic diagram of an information processing system of asecond example.

FIG. 9 is a block configuration diagram of a node device of the secondexample.

FIG. 10 is a task table of the node device of the second example.

FIG. 11 is a schematic diagram of an information processing system of athird example.

FIG. 12 is a task table of a node device of the third example.

FIG. 13 is a task table of another node device of the third example.

FIG. 14 is a schematic diagram of an information processing system of afourth example.

FIG. 15 is a task table of a node device of the fourth example.

FIG. 16 is an index table of a gateway device of the fourth example.

FIG. 17 is a flowchart illustrating an operating procedure of thegateway device of the fourth example.

DESCRIPTION OF THE EMBODIMENTS Embodiment

Hereinafter, an information processing system (facility monitoringsystem) of an embodiment of the present invention will be described withreference to the accompanying drawings.

FIG. 1 is a schematic diagram of a production facility to which theinformation processing system of an embodiment has been applied. Theproduction facility 101 includes sensors 102 and 103 used to obtain thestate of the production facility 101. Each of the sensors 102 and 103may be a vibration sensor, an acceleration sensor, a pressure sensor, aphotosensor, a torque sensor, or a temperature sensor; and measures thestate of the production facility 101 and quantifies the state as aphysical quantity. Thus, the information processing system obtains thestate of the production facility 101 by using the sensors 102 and 103,and thereby monitors the production facility 101.

For obtaining the state of the production facility 101, a node device104 is connected with at least one of the sensors 102 and 103. Thesensors 102 and 103 may be included in the node device 104. The nodedevice 104 is one or more in number, determined as necessary; and isdisposed in the production facility 101. The node device 104 includescommunication units 109, which allow the node device 104 to communicatewith a gateway device 105. The communication units include one or morecommunication portions, selected appropriately from wirelesscommunications including low power wide area (LPWA) and wireless LAN,and wire communications including the Ethernet and Field Network.

The measurement data measured by the sensors is collected in the gatewaydevice 105 from the node device 104 via the communication units 109 and110. The gateway device 105 is connected with an in-plant network 106.Note that the in-plant network 106 may be a dedicated network used in aplant (LAN), or may be a wide area network such as the Internet. Thegateway device 105 is installed in an area in which the gateway device105 can communicate with the node device 104 via the communication units109 and 110.

The measurement data collected in the gateway device 105 is stored in adatabase 107 of a data storage device connected to the in-plant network106. Note that the function of the gateway device 105 may be implementedas software in the database 107 or a storage portion of a computer. Inaddition, the database 107 may be a storage device or a storage medium.

An administrator can check the resultant data stored in the database107, by using a computer 108. If an abnormal state occurs in theproduction facility 101, the computer 108 can notify the administratorof the abnormal state, if necessary. For example, the computer 108 mayissue an alert, or send a mail to the administrator.

FIG. 2 is a schematic diagram illustrating a block configuration of thenode device 104 of FIG. 1. The node device 104 is connected with asensor 203 that is one or more sensors disposed in the productionfacility 101. The node device 104 includes a signal input portion (A/Dconverter)204, which converts an analog signal outputted from the sensor203, to a digital signal. The signal input portion 204 converts one ormore analog input signals to digital signals. Note that the signal inputportion 204 may be included in the sensor 203, and the sensor 203 mayoutput the digital signals.

The signal digitized by the signal input portion 204 is processed by aCPU 205. The CPU 205 selects one or more of the following processes:no-operation process, FFT process, partial overall process, envelopprocess, frequency filter process, differential process, integralprocess, wavelet process, average value process, standard deviationprocess, maximum value process, minimum value process, peak-to-peakprocess, peak hold process, effective value process, crest factorprocess, form factor process, impulse coefficient process, margincoefficient process, and machine-learning-model inference process,determines the order of the selected processes, and executes them.

For example, in the no-operation process, the CPU 205 does not processthe digitized input signal, and delivers the digitized signal to anoutput portion 206. In the FFT process, the CPU 205 decomposes thedigitized input signal into frequency components. In the partial overallprocess, the CPU 205 determines a frequency range, and sums theFFT-processed frequency components in the determined frequency range. Inthe envelop process, the CPU 205 determines an envelope of the inputsignal. In the frequency filter process, the CPU 205 sets a frequencyrange, and causes the input signal to pass through a low-pass filter, ahigh-pass filter, or a band-pass filter for eliminating undesiredsignals and obtaining an intended signal.

In the differential process, the CPU 205 differentiates the inputsignal. In the integral process, the CPU 205 integrates the inputsignal. In the wavelet process, the CPU 205 decomposes the digitizedinput signal into frequency components and time components. In theaverage value process, the CPU 205 calculates an average value of theinput signal. In the standard deviation process, the CPU 205 calculatesa standard deviation of the input signal. In the maximum value process,the CPU 205 calculates a maximum value of the input signal. In theminimum value process, the CPU 205 calculates a minimum value of theinput signal. In the peak-to-peak process, the CPU 205 calculates adifference between the maximum value and the minimum value of the inputsignal. In the peak hold process, the CPU 205 measures the input signalcontinuously in a predetermined period of time, and calculates a maximumvalue of the input signal in the predetermined period of time. In theeffective value process, the CPU 205 calculates an effective value ofthe input signal.

In the crest factor process, the CPU 205 calculates a crest factor ofthe input signal by dividing a maximum value of the input signal by aneffective value of the input signal. In the form factor process, the CPU205 calculates a form factor of the input signal by dividing aneffective value of the input signal by an average value of the inputsignal. In the impulse coefficient process, the CPU 205 calculates animpulse coefficient of the input signal by dividing a maximum value ofthe input signal by an absolute average value of the input signal. Inthe margin coefficient process, the CPU 205 calculates a margincoefficient of the input signal by dividing a maximum value of the inputsignal by a value of the input signal. The value is obtained bycalculating a square root of an average value of the input signal, andthen calculating a square of the square root value. In themachine-learning-model inference process, a computer creates a machinelearning model (learned model) in advance by reading and analyzinglearning data. In the machine learning model, rules for classificationand identification are defined. The machine learning model isimplemented in the node device 104, and the CPU 205 determines theoutput depending on the input signal and the machine learning model.

Note that although the above-described various types of signalprocessing are performed by the CPU 205, they may be performed by adedicated piece of hardware such as a PLA.

The node device 104 includes the output portion 206 that outputs asignal processed by the CPU 205. The output portion 206 operates underthe control of the CPU 205, and includes at least one of awireless-communication unit 207 and a wire-communication unit 208. Inaddition to the wireless-communication unit 207 and/or thewire-communication unit 208, the output portion 206 can select at leastone of a storage portion 209 and a general-purpose input/output portion211, and can output measurement data to a selected portion.Specifically, the output portion 206 can add a node number (nodeidentification information) and a measurement task number (taskidentification information) to measurement data, and output themeasurement data. The node number serves as identification informationused to identify the node device 104 as an individual device. The outputportion 206 uses wireless communications or wire communications, andoutputs the node number, the measurement task number, and themeasurement data to the gateway device 105 in this order. Thewire-communication unit 208 is connected to the gateway device 105 via asensor network 210.

The node device 104 includes an event generation portion 202 that isactivated at diagnosis intervals or a diagnosis time, which ispredetermined as a timer trigger, or is activated by a trigger inputtedvia the general-purpose input/output portion 211. The event condition ofthe event generation portion 202 includes at least one of apredetermined measurement interval, a time, an external-trigger inputsignal, a change in the state of the node device, a call from anothertask of the node device, a call from the gateway device, and a call fromanother node device. If a plurality of event generation conditions isselected, the measurement is started when any one of the selectedconditions is satisfied.

The event generation portion 202 may be a dedicated piece of hardwaresuch as a PLA, or may be a piece of software that is a control programfor controlling the operation of the CPU 205.

For example, if the event condition is measurement intervals, events aregenerated at predetermined intervals. If the event condition is a time,an event is generated, for example, at a predetermined time on apredetermined day of the week. If the event condition is anexternal-trigger input signal, an event is generated when a signal fromthe general-purpose input/output portion 211 changes. If the eventcondition is a change in the state of the node device, an event isgenerated when the remaining battery level of the node device changes,or when a signal from a temperature sensor of the node device changes.If the event condition is a call from another task of the node device,an event is generated when the event generation portion 202 is calledfrom the other task of the node device under the output condition of theother task. If the event condition is a call from the gateway device, anevent is generated when the node device receives a task executioncommand from the gateway device. If the event condition is a call fromanother node device, an event is generated when the event generationportion 202 is called from the other node device under the outputcondition of the other node device.

The event condition of the event generation portion 202, the signalinput condition of the signal input portion 204, the signal processingcondition of the CPU 205, and the output condition of the output portion206 are stored, as components of a measurement task, in a task table ofthe storage portion 209. Note that although the task table is stored inthe storage portion 209, the task table may be stored in another storagedevice.

FIG. 3 is a schematic diagram illustrating a block configuration of thegateway device 105 illustrated in FIG. 1. The gateway device 105includes a wire-communication unit 304 for communicating via wire withthe node device 104, via a sensor network 303 (210). In addition, thegateway device 105 includes a wireless-communication unit 302 forcommunicating wirelessly with the node device 104. The unit that allowsthe gateway device 105 and the node device 104 to communicate with eachother may be the wire-communication unit 304 or thewireless-communication unit 302, depending on an environment where thenode device 104 is installed.

The gateway device 105 includes a CPU 308 that controls the operation ofeach unit. The gateway device 105 has an index table stored in a storagedevice 305. The index table is used to associate measurement data with acorresponding table of the database 107 (FIG. 1) by using anode numberand a task number. The node number is used to identify the node device104 as an individual device. The CPU 308 of the gateway device 105determines a table of the database 107 in which the measurement data isto be stored, by using the node number of the node device 104, themeasurement task number, and information of the index table. The gatewaydevice 105 receives measurement data from the node device 104 via thewire-communication unit 304 or the wireless-communication unit 302, andstores the measurement data in a table of the database 107 via anin-plant network 307 (106) connected with a wire-communication unit 306.Note that the sensor network 303 and the in-plant network 307 may be anidentical network.

The table illustrated in FIG. 4 is a task table 401 of the node device104. The node device 104 has the task table 401, which is stored in thestorage portion 209 as information. The task table 401 includes a tasknumber 402 assigned to a corresponding task, an event condition 403 ofthe event generation portion 202, a signal input condition 404 of thesignal input portion 204, a signal processing condition 405 of the CPU205, an output processing condition 406 of the output portion 206, and anode number 407. In the task table 401 of the node device 104, one ormore measurement tasks are registered in advance, in accordance withmeasurement items and sensors connected to the node device 104. Themeasurement tasks registered in the task table 401 are executedsequentially in the order from a measurement task whose event condition403 has been satisfied. The task whose event condition 403 has beensatisfied is executed under the signal input condition 404, the signalprocessing condition 405, and the output processing condition 406.

The table illustrated in FIG. 5 is an index table 501 of the gatewaydevice 105. The gateway device 105 has the index table 501, which isstored in the storage device 305 as information. The index table 501includes a node number 502 of the node device 104, a task number 503that indicates a number assigned to a corresponding task of the nodedevice 104 registered in the task table 401, a receiving means 505, adatabase name 504 indicating a data storage device where data is to bestored, and a table name 506 that defines an area of the database wherethe data is to be stored. The index table 501 is registered in advance,associated with the node device 104 connected to the gateway device 105and with the task table 401 of the node device 104. Upon receivingmeasurement data from the node device 104, the gateway device 105searches the index table 501 for a node number 502 and a task number 503included in the received measurement data. The gateway device 105 thenregisters the measurement data by using the information on the databasename 504 and the table name 506 corresponding to the node number 502 andthe task number 503 of the index table 501.

FIG. 6 is a flowchart of processes in which the node device 104 obtainsthe state of the production facility 101. The following description willbe made for processes in which the state of the production facility 101is obtained by using the task table.

In Step S1, the CPU 205 of the node device 104 starts to obtain thestate of the production facility 101. In Step S2, the CPU 205 readstasks that have been registered in advance, from the task table 401 ofthe storage portion 209.

In Step S3, the CPU 205 resisters an event condition 403 of each task,which is registered in the task table 401, in the event generationportion 202.

In Step S4, the CPU 205 of the node device 104 refers to the eventregistered in Step S3, and checks whether an event, such as a specifiedtime, a specified interval, or an external input, has occurred.

If an event has occurred, then the CPU 205 executes a task correspondingto the event. In Step S5, the CPU 205 sets the signal input portion 204by selecting a signal input condition 404 including a physical-quantityinput channel, a sampling frequency, an input range, the number ofsamples, and an amplification factor, which are registered in the tasktable 401.

In Step S6, the CPU 205 performs a signal input process, such asanalog-digital conversion, under the signal input condition 404 that hasbeen set. In Step S7, the CPU 205 selects a signal processing condition405 registered in the task table 401, and performs the setting of theCPU 205. In Step S8, the CPU 205 performs signal processing on thedigitalized measurement data. In Step S9, for handling thesignal-processed measurement data, the CPU 205 sets the output portion206 under an output processing condition 406 registered in the tasktable 401.

In Step S10, the CPU 205 adds a node number 407 of the node device 104and a task number 402 corresponding to the event, to the measurementdata. Note that if the output condition (output destination) is thestorage device, only the task number may be added to the measurementdata because the node number is known. In Step S11, the measurement datato which the node number and the measurement task number have been addedis outputted to the gateway device, the general-purpose input/outputportion of the output portion 206, or the storage device of the outputportion 206, under the output processing condition 406. When Step S11 iscompleted, the CPU 205 returns to Step S4, and checks whether an eventhas occurred again.

FIG. 7 is a flowchart for illustrating a procedure in which the gatewaydevice 105 collects and processes measurement data for obtaining thestate of the production facility. The following description will be madefor a procedure in which the gateway device 105 registers themeasurement data sent from the node device 104, in a database forobtaining the state of the production facility.

In Step S51, the CPU 308 of the gateway device 105 starts to obtain thestate of the production facility 101. In Step S52, the CPU 308 reads theindex table 501 that has been registered in advance in the storagedevice 305.

In Step S53, the CPU 308 of the gateway device 105 selects a receivingunit to receive measurement data from the node device 104, depending ona receiving means 505 registered in the index table 501. If a pluralityof receiving means are registered in the index table 501, the gatewaydevice 105 selects a plurality of receiving units.

In Step S54, the CPU 308 of the gateway device 105 checks whether onereceiving unit has received measurement data from the node device 104.If the receiving unit receives measurement data from the node device104, then the gateway device 105 proceeds to Step S55, and extracts anode number of the node device and a task number from the measurementdata.

In Step S56, the CPU 308 searches the index table 501 for indexes byusing the node number and the task number. Then the CPU 308 determines atable of a database where the measurement data is to be stored,depending on the indexes that the CPU 308 has found. In Step S57, theCPU 308 creates a query to store the measurement data. In Step S58, theCPU 308 of the gateway device 105 executes the query and stores themeasurement data in the table of the database. When Step S58 iscompleted, the CPU 308 returns to Step S54, and checks whether thereceiving unit has received measurement data again.

In the present embodiment, since the communication is performedefficiently, the gateway device can easily determine, even in a limitedcommunication band, that one piece of measurement data has been sentfrom which node device, or measured in which measurement task. Inaddition, since the communication is performed efficiently, the powerconsumption of the node device can be reduced.

Next, some specific examples will be described. In a first example,measurement is performed depending on a recipe, and the measurementresult is stored in a data storage device. In a second example, in anabnormal state, measurement is performed depending on another recipe. Ina third example, in an abnormal state, measurement is performed byanother node device, depending on a recipe of the other node device. Ina fourth example, if the gateway device receives measurement data from anode device that is not registered in the index table, the gatewaydevice stores the measurement data in a database, as test data.

First Example

The first example of the present embodiment will be described withreference to the accompanying drawings. FIG. 1 is a schematic diagram ofa production facility that includes an information processing system ofthe first example.

A pump serves as the production facility 101, and includes vibrationsensors 102 and 103 for obtaining the operation state. The vibrationsensors 102 and 103 convert the strength of vibration to a voltagesignal, as a physical quantity. The vibration sensors 102 and 103 areconnected to a node device 104, and obtain the state of the pump, whichserves as the production facility 101. The node device 104 includescommunication units 109, which allow the node device 104 to communicatewith the gateway device 105. For example, the node device 104 includesan LPWA (low power wide area) wireless-communication unit.

The node device 104 performs measurement, depending on a task table 401stored in advance in a storage portion 209. Specifically, the nodedevice 104 performs measurement under an event condition 403, which isset in the task table 401 of FIG. 4.

In a task 1 in which a task number 402 is 1, since the event condition403 is set so that events occur at intervals of 60 minutes, the task 1is executed once every 60 minutes. Specifically, the elapsed time isreset when the power of the node device 104 is turned on, and the task 1is executed every time 60 minutes has elapsed. When the task 1 isexecuted, the analog-digital conversion is performed under a signalinput condition 404: an analog-digital conversion channel of 1; asampling frequency of 54 kHz; an input range from 0 to 5 V; the numberof samples of 10,000; and an amplification factor of 50. In the task 1,after the analog-digital conversion, the CPU 205 performs the FFTprocess and then the partial overall process under a signal processingcondition 405. Since wireless communication is selected under an outputprocessing condition 406 for the task 1, the CPU 205 adds the number ofthe node device 104 and the task number of 1 to the measurement data,and sends the measurement data to the gateway device 105 via awireless-communication unit 207.

In a task 2 in which a task number 402 is 2, the task 2 is executed at15:00 on every Monday, under an event condition 403. When the task 2 isexecuted, the analog-digital conversion is performed under a signalinput condition 404: an analog-digital conversion channel of 2; asampling frequency of 54 kHz: an input range from 0 to 5 V; the numberof samples of 10,000; and an amplification factor of 50. In themeasurement task 2, after the analog-digital conversion, the CPU 205performs the FFT process under a signal processing condition 405. Sincewire communication is selected under an output processing condition 406for the measurement task 2, the CPU 205 adds the number of the nodedevice 104 and the task number of 2 to the measurement data, and sendsthe measurement data to the gateway device 105 via a wire-communicationunit 208.

The gateway device 105 receives measurement data, to which the nodenumber 104 and the task number 1 have been added, from the node device104 via the wireless-communication unit 302 every time the task 1 isexecuted at an interval of 60 minutes. The gateway device 105 extractsthe number of the node device 104 and the task number of 1 from themeasurement data, and searches the index table 501 (FIG. 5) of thestorage device 305.

If the node number is 104 and the task number is 1, the gateway device105 finds a database name 504 of DB1 and a table name 506 of TBL3, whichhave been registered in advance in the index table 501. The gatewaydevice 105 creates a query to store the measurement data in the tableTBL3 of the database DB1, and stores the measurement data in the tableTBL3 of the database 107 (DB1), via the in-plant network 307.

Similarly, when the measurement task 2 is executed at 15:00 on everyMonday, the gateway device 105 receives measurement data, to which thenode number 104 and the task number 2 have been added, from the nodedevice 104 via the wire-communication unit 304. The gateway device 105creates a query to store the measurement data in a table TBL4 of thedatabase 107 (DB1), and stores the measurement data in the table TBL4 ofthe database 107 (DB1), via the in-plant network 307.

The node device 104 has a plurality of measurement tasks. Thus, if thegateway device receives only the measurement data, the gateway devicecannot distinguish the measurement task from the other measurementtasks. Consequently, the gateway device cannot store the measurementdata in a corresponding table of a corresponding database specified forthe measurement task. In addition, if the node device 104 specifies adatabase and a table for storing measurement data, the amount of senddata will increase, possibly shortening the battery life of the nodedevice and making it difficult for the communication band to accommodatethe send data.

In the present example, since the node number and the task number areadded to the measurement data by the node device, the battery life ofthe node device can be secured, and each measurement data can beidentified by the gateway device. In addition, the present example canprovide a measuring means that can set a plurality of measurementconditions.

Second Example

The second example of the present embodiment will be described withreference to the accompanying drawings. FIG. 8 is a schematic diagram ofan information processing system. The following description will be madefor a procedure in which detailed measurement is performed when a bladeof a pump of a production facility is damaged for example and abnormalvibration is occurring.

For obtaining the operation state of a pump 801, a channel 1 of a nodedevice 802 is connected to a vibration sensor 803, and a channel 2 ofthe node device 802 is connected to a temperature sensor 804. In a tasktable of the node device 802, a measurement task 1, a measurement task2, and a measurement task 3 have been registered in advance.

FIG. 9 illustrates a block configuration diagram of the node device, andFIG. 10 illustrates a task table 1001 of the node device.

A node device 802 is connected to the vibration sensor 803 and thetemperature sensor 804, which are illustrated in FIG. 9 as a sensor 903.The node device 802 includes a signal input portion 904, which convertsan analog signal outputted from the sensor 903, to a digital signal.That is, the signal input portion 904 converts an analog input signal toa digital signal. Note that the signal input portion 904 may be includedin the sensor 903.

The signal digitized by the signal input portion 904 is processed by aCPU 905. The CPU 905 selects one or more of the following processes:no-operation process, FFT process, partial overall process, envelopprocess, frequency filter process, differential process, integralprocess, wavelet process, average value process, standard deviationprocess, maximum value process, minimum value process, peak-to-peakprocess, peak hold process, effective value process, crest factorprocess, form factor process, impulse coefficient process, margincoefficient process, and machine-learning-model inference process, anddetermines the order of the selected processes.

The node device 802 includes an output portion 906 that outputs a signalprocessed by the CPU 905. The output portion 906 includes a thresholddetermination portion 912, which selects an output destination dependingon a result of a process performed by the CPU 905. In addition, theoutput portion 906 includes at least one of a wireless-communicationunit 907 and a wire-communication unit 908. Under the control of the CPU905, the output portion 906 selects at least one of thewireless-communication unit 907, the wire-communication unit 908, astorage portion 909, and a general-purpose input/output portion 911, asan output destination. The CPU 905 associates a result of a processperformed by the CPU 905, with a node number 1007 and a task number 1002(FIG. 10), and outputs the result as measurement data. The node number1007 is a number to identify the node device 802 as an individualdevice.

The wire-communication unit 908 is connected to a gateway device 851 viaa sensor network 910. The node device 802 includes an event generationportion 902 that is activated at diagnosis intervals or a diagnosistime, which is predetermined as a timer trigger, or is activated by atrigger inputted via the general-purpose input/output portion 911.

The event condition of the event generation portion 902 is stored, as acomponent of a measurement task, in a task table of the storage portion909, together with the signal input condition of the signal inputportion 904, the signal processing condition of the CPU 905, and theoutput condition of the output portion 906. Note that although the tasktable is stored in the storage portion 909, the task table may be storedin another storage device.

A task 1 is executed under an event condition 1003, once every 60minutes. When the task 1 is executed, the analog-digital conversion isperformed under a signal input condition 1004: an analog-digitalconversion channel of 1; a sampling frequency of 54 kHz; an input rangefrom 0 to 5 V; the number of samples of 10,000; and an amplificationfactor of 50. In the task 1, after the analog-digital conversion, theCPU 905 performs the frequency filter process and then the average valueprocess under a signal processing condition 1005. In the task 1,wireless communication and conditional measurement tasks 2 and 3 areselected under an output condition 1006. The CPU 905 adds the nodenumber 802 and the task number 1 to the measurement data, and sends themeasurement data to a gateway device 851 via the wireless-communicationunit 907. The gateway device 851 registers the measurement data, towhich the node number 1007 (802) and the task number 1002 (1) have beenadded, in a database 853 via a network 852.

For example, if a blade 805 of the pump 801 is damaged and abnormalvibration is occurring, an average value of measurement data in the task1 exceeds 50.0 m/s², and the threshold determination portion 912 of theoutput portion 906 determines that the average value has exceeded thethreshold (a predetermined condition has been satisfied). Then, the nodedevice sends the measurement data to the gateway device 851, andexecutes the measurement tasks 2 and 3. The node device 802 then sendsthe result of the measurement tasks 2 and 3, to the gateway device 851under an output condition 1006.

In the task 2, detailed measurement is performed by using the vibrationsensor. In the measurement task 2, the analog-digital conversion isperformed under a signal input condition 1004: an analog-digitalconversion channel of 1; a sampling frequency of 54 kHz; an input rangefrom 0 to 5 V; the number of samples of 10,000; and an amplificationfactor of 50. In the measurement task 2, after the analog-digitalconversion, the CPU 905 performs the FFT process under a signalprocessing condition 1005. Since wireless communication is selectedunder an output condition 1006, the CPU 905 adds the node number 802 andthe task number 2 to the measurement data, and sends the measurementdata to the gateway device 851 via the wireless-communication unit. Thegateway device 851 registers the measurement data, to which the nodenumber 1007 (802) and the task number 1002 (2) have been added, in thedatabase 853 via the network 852.

In the measurement task 3, measurement is performed by using thetemperature sensor. In the measurement task 3, the analog-digitalconversion is performed under a signal input condition 1004: ananalog-digital conversion channel of 2; a sampling frequency of 54 kHz;an input range from 0 to 5 V; the number of samples of 10,000; and anamplification factor of 1. In the measurement task 3, after theanalog-digital conversion, the CPU 905 preforms the frequency filterprocess and then the average value process under a signal processingcondition 1005. Since wireless communication is selected under an outputcondition 1006, the CPU 905 adds the node number 802 and the task number3 to the measurement data, and sends the measurement data to the gatewaydevice 851 via the wireless-communication unit. The gateway device 851registers the measurement data, to which the node number 1007 (802) andthe task number 1002(3) have been added, in the database 853 via thenetwork 852.

In the present example, the output portion includes the thresholddetermination portion, which selects an output condition depending on adetermination result. Thus, the battery life can be secured, anddetailed measurement can be performed in accordance with the result of atask, in a limited communication band.

Third Example

The third example of the present embodiment will be described withreference to the accompanying drawings. FIG. 11 is a schematic diagramof an information processing system. The following description will bemade for a procedure in which when a blade of a pump of a productionfacility is damaged and abnormal vibration is occurring, a task ofanother node device is called depending on a measurement result of onenode device.

For obtaining the operation state of a pump 1101, a channel 1 of a nodedevice 1102 is connected to a vibration sensor 1104, and a channel 1 ofa node device 1103 is connected to a temperature sensor 1105. FIG. 12illustrates a task table 1201 of the node device 1102. In the task table1201, a measurement task 1 has been registered in advance. In addition,in a task table 1301 of the node device 1103, a measurement task 1 and ameasurement task 2 have been registered in advance. The output portion906 (FIG. 9) of the node device 1102 includes the thresholddetermination portion 912.

FIG. 13 illustrates the task table 1301 of the node device 1103. In thetask table 1301, the task 1 is set so as to be executed at 15:00 onevery Monday under an event condition 1303. In addition, the measurementtask 2 is set so as to be executed when called from another node device,under an event condition 1303.

As illustrated in FIG. 12, the task 1 of the node device 1102 isexecuted under an event condition 1203, once every 60 minutes. When thetask 1 is executed, the analog-digital conversion is performed under asignal input condition 1204: an analog-digital conversion channel of 1;a sampling frequency of 54 kHz; an input range from 0 to 5 V; the numberof samples of 10,000; and an amplification factor of 50. In the task 1,after the analog-digital conversion, the CPU 905 (FIG. 9) performs thefrequency filter process and then the average value process under asignal processing condition 1205.

In the task 1, wireless communication and conditional call to themeasurement task 2 of the node device 1103 are selected under an outputcondition 1206. The CPU 905 adds a node number 1102 and a task number 1to the measurement data of the task 1, and sends the measurement datafrom the node device 1102 to a gateway device 1151 via thewireless-communication unit 907. The gateway device 1151 registers themeasurement data, to which the node number 1207 (1102) and the tasknumber 1202 (1) have been added, in a database 1153 via a network 1152.In addition, if a condition is satisfied, the node device 1102 calls themeasurement task 2 of the node device 1103 via thewireless-communication unit 907, under the output condition 1206.

For example, if a blade 1106 of the pump 1101 is damaged and abnormalvibration is occurring, an average value of measurement data in the task1 exceeds 50.0 m/s², and the threshold determination portion 912 of theoutput portion 906 determines that the average value has exceeded thethreshold (a predetermined condition has been satisfied). If the nodedevice 1102 determines that abnormal vibration is occurring, the nodedevice 1102 sends an instruction to the node device 1103 via thewireless-communication unit 907 for causing the node device 1103 toexecute the measurement task 2 for immediately measuring thetemperature.

Upon receiving the instruction to execute the measurement task 2, fromthe node device 1102 via the wireless-communication unit 907, the nodedevice 1103 executes the measurement task 2. The node device 1103 isconnected to the temperature sensor attached to the pump 1101. When themeasurement task 2 is executed, the analog-digital conversion isperformed under a signal input condition 1304: an analog-digitalconversion channel of 1; a sampling frequency of 54 kHz; an input rangefrom 0 to 5 V; the number of samples of 10,000; and an amplificationfactor of 1. After the analog-digital conversion, the CPU 905 of thenode device 1103 performs the frequency filter process and then theaverage value process under a signal processing condition 1305. Sincewireless communication is selected under an output processing condition1306, the CPU 905 adds a node number 1103 and a task number 2 to themeasurement data, and sends the measurement data to the gateway device105 via the wireless-communication unit. The gateway device 1151registers the measurement data, to which the node number 1307 (1103) andthe task number 1302 (2) have been added, in the database 1153 via thenetwork 1152.

In the present example, since a call to a task of another node device isset in the output condition, one node device can perform detailedmeasurement in cooperation with another node device if an error occursin the pump.

Fourth Example

The fourth example of the present embodiment will be described withreference to the accompanying drawings. The following description willbe made for a procedure in which when the gateway device receivesmeasurement data from a node device that has been newly installed in aproduction facility and that has not been registered in the index tableof the gateway device, the gateway device stores the measurement data ina database, as test data, separately from normal measurement data.

FIG. 14 illustrates a schematic diagram of an information processingsystem of the present example. For obtaining the state of a productionfacility 1401, a vibration sensor 1404 is disposed in the productionfacility 1401, and is connected with a node device 1402.

For obtaining the detailed state of the production facility 1401, atemperature sensor 1405 has been newly attached to the productionfacility 1401, and a node device 1403 has been newly installed. FIG. 15illustrates a task table 1501 of the newly installed node device 1403.In the task table 1501, a task 1 has been registered in advance. Thetask 1 is executed under an event condition 1503, at 15:00 on everyMonday.

When the task 1 is executed, the analog-digital conversion is performedunder a signal input condition 1504: an analog-digital conversionchannel of 1; a sampling frequency of 54 kHz; an input range from 0 to 5V; the number of samples of 10,000; and an amplification factor of 1. Inthe task 1, after the analog-digital conversion, the CPU of the nodedevice 1403 performs the frequency filter process and then the averagevalue process under a signal processing condition 1505.

As illustrated in FIG. 15, in the task 1, wireless communication isselected under an output condition 1506. The CPU adds a node number 1403and a task number 1 to the measurement data, and sends the measurementdata to a gateway device 1451 via the wireless-communication unit 907.

FIG. 16 illustrates an index table 1601 of the gateway device 1451. Inthe index table 1601, tasks having node numbers 1602 of 1402 and 1450have been registered in advance. However, the newly installed nodedevice 1403, illustrated by a dotted line frame in FIG. 16, has not beenregistered in the index table 1601.

FIG. 17 is a flowchart illustrating a flow of processes of the presentexample. In Step S71, the gateway device 1451 starts to obtain the stateof the production facility 1401. In Step S72, the gateway device 1451reads the index table 1601 that has been registered in advance in thestorage device 305.

In Step S73, the gateway device 1451 selects a unit to receivemeasurement data from the node devices 1402, depending on a receivingunit 1605 registered in the index table 1601. If a plurality ofreceiving units 1605 are registered in the index table 1601, the gatewaydevice 1451 selects the plurality of receiving units 1605.

In Step S74, the gateway device 1451 checks whether one receiving unit1605 (FIG. 16) has received measurement data from a node device. If thereceiving unit 1605, which is registered in the index table 1601,receives measurement data from the node device, the gateway device 1451proceeds to Step S75, and extracts a node number and a task number fromthe measurement data sent from the node device.

In Step S76, the gateway device 1451 refers to the node number and thetask number, and searches the indexes of the index table 1601. If thegateway device 1451 finds the node number and the task number in theindex table 1601, then the gateway device 1451 proceeds to Step S77 andcreates a query, and registers the measurement data, in Step S78, in adatabase 1453 via a network 1452. That is, the gateway device 1451registers the measurement data, to which the node number 1602 (1402) andthe task number 1603 have been added, in a registration destinationidentified by a database name 1604 and a table name 1606 of the indextable 1601.

If the gateway device 1451 receives measurement data from the newlyinstalled node device 1403, the gateway device 1451 cannot find the nodenumber and the task number in Step S76 because they have not beenregistered in the index table 1601. In this case, the gateway device1451 proceeds to Step S79, and creates a query for storing themeasurement data in a predetermined measurement-test table of thedatabase. In Step S80, the gateway device 1451 stores the testmeasurement data in the table of the database 1453 via the in-plantnetwork 1452. That is, the gateway device 1451 stores the measurementdata, to which the unregistered node number and the unregistered tasknumber 1603 have been added, in the registration destination identifiedby a database name 1604 and a table name 1606 of the index table 1601.

Note that although the description has been made in the present examplefor the case where the node number of a node device has not beenregistered, the measurement data is also handled as test data andregistered in the database 1453 if the node number has been registeredbut the task number has not been registered. That is, the gateway device1451 registers the measurement data, to which a node number 1602 and anunregistered task number have been added, in a registration destinationidentified by a database name 1604 and a table name 1606 of the indextable 1601.

In the present example, if the gateway device receives measurement datafrom a node device that has been newly installed in a productionfacility or measurement data from a task that has been newly installedon an existing node device, and the newly installed node device or thenewly installed task has not been registered in the index table of thegateway device, the gateway device stores the measurement data in adatabase, as test data, separately from normal measurement data. Withthis operation, it is possible to check whether the newly installed nodedevice is operating normally, and whether the newly installed task isbeing performed normally. Note that since the term “test data” is usedexpediently in the above description, any other term may be used as longas the term means the data related to an unregistered node device or anunregistered task.

Modifications

The present invention is not limited to the above-described embodimentsand examples, and can be variously modified within the technical conceptof the present invention.

The information processing system of the present invention can be usedfor monitoring the state of not only the production facility but alsovarious machines and facilities, such as industrial robots, servicerobots, and processing machines that are numerically controlled by acomputer. Mechanical equipment and an information processing device maybe combined into the information processing system, or the informationprocessing device may be installed as part of the mechanical equipment.

A method that manufactures products by using a production facility whilecausing the information processing system of the present invention toobtain the state of the production facility is also included in theembodiments of the present invention. A production facility thatincludes the information processing system of the present invention isalso included in the embodiments of the present invention, as amanufacturing system with a high operating ratio.

The above-described information processing system of the embodiment canbe embodied as a system that obtains the state of various facilitiesincluding a robot which is operated in a production line, and thatmonitors the facilities. For example, the facilities are mechanicalequipments that can automatically perform expansion and contraction,bending and stretching, up-and-down movement, right-and-left movement,pivot, or combined movement thereof, in accordance with informationstored in the storage device of the control device.

The above-described information processing method (control method) forobtaining the state of a facility, and a computer-readable recordingmedium that stores a control program that can execute the informationprocessing method (control method) is also included in the embodimentsof the present invention. The recording medium for providing the controlprogram may be a ROM, a disk, or an external storage device.Specifically, the computer-readable non-transitory recording medium maybe a flexible disk, an optical disk, a magneto-optical disk, a magnetictape, a nonvolatile memory such as a USB memory, an SSD, or the like.

OTHER EMBODIMENTS

Embodiment(s) of the present invention can also be realized by acomputer of a system or apparatus that reads out and executes computerexecutable instructions (e.g., one or more programs) recorded on astorage medium (which may also be referred to more fully as a‘non-transitory computer-readable storage medium’) to perform thefunctions of one or more of the above-described embodiment(s) and/orthat includes one or more circuits (e.g., application specificintegrated circuit (ASIC)) for performing the functions of one or moreof the above-described embodiment(s), and by a method performed by thecomputer of the system or apparatus by, for example, reading out andexecuting the computer executable instructions from the storage mediumto perform the functions of one or more of the above-describedembodiment(s) and/or controlling the one or more circuits to perform thefunctions of one or more of the above-described embodiment(s). Thecomputer may comprise one or more processors (e.g., central processingunit (CPU), micro processing unit (MPU)) and may include a network ofseparate computers or separate processors to read out and execute thecomputer executable instructions. The computer executable instructionsmay be provided to the computer, for example, from a network or thestorage medium. The storage medium may include, for example, one or moreof a hard disk, a random-access memory (RAM), a read only memory (ROM),a storage of distributed computing systems, an optical disk (such as acompact disc (CD), digital versatile disc (DVD), or Blu-ray Disc (BD)™),a flash memory device, a memory card, and the like.

While the present invention has been described with reference toexemplary embodiments, it is to be understood that the invention is notlimited to the disclosed exemplary embodiments. The scope of thefollowing claims is to be accorded the broadest interpretation so as toencompass all such modifications and equivalent structures andfunctions.

This application claims the benefit of Japanese Patent Application No.2020-50521, filed Mar. 23, 2020, and Japanese Patent Application No.2020-179431, filed Oct. 27. 2020, which are hereby incorporated byreference herein in their entirety.

What is claimed is:
 1. An information processing system comprising: a plurality of node devices, each of the plurality of node devices being connected to a sensor configured to measure a state of a facility, and being configured to execute a measurement task; and a gateway device configured to communicate with the plurality of node devices, wherein each of the plurality of node devices is configured to add node identification information used to identify the node device and task identification information used to identify the measurement task executed by the node device, to measurement data acquired in the measurement task, and send the measurement data to the gateway device.
 2. The information processing system according to claim 1, wherein if the gateway device receives the measurement data to which the node identification information and the task identification information have been added, the gateway device stores the measurement data to which the node identification information and the task identification information have been added, in a database.
 3. The information processing system according to claim 1, wherein at least one of the plurality of node devices is configured to execute another measurement task if a result of one measurement task performed by the at least one of the plurality of node devices satisfies a predetermined condition.
 4. The information processing system according to claim 1, wherein at least one of the plurality of node devices is configured to send an instruction that causes another node device to execute another measurement task, if a result of one measurement task performed by the at least one of the plurality of node devices satisfies a predetermined condition.
 5. An information processing method that uses an information processing system, the information processing system comprising: a plurality of node devices, each of the plurality of node devices being connected to a sensor configured to measure a state of a facility, and being configured to execute a measurement task; and a gateway device configured to communicate with the plurality of node devices, the information processing method comprising: adding, by each of the plurality of node devices, node identification information used to identify the node device and task identification information used to identify the measurement task executed by the node device, to measurement data acquired in the measurement task, and sending the measurement data to the gateway device.
 6. The information processing method according to claim 5, wherein if the gateway device receives the measurement data to which the node identification information and the task identification information have been added, the gateway device stores the measurement data to which the node identification information and the task identification information have been added, in a database.
 7. The information processing method according to claim 5, further comprising-executing another measurement task by at least one of the plurality of node devices, if a result of one measurement task performed by the at least one of the plurality of node devices satisfies a predetermined condition.
 8. The information processing method according to claim 5, further comprising: sending, by at least one of the plurality of node devices, an instruction that causes another node device to execute another measurement task, if a result of one measurement task performed by the at least one of the plurality of node devices satisfies a predetermined condition.
 9. A computer-readable non-transitory recording medium storing a control program that causes a computer to execute the information processing method according to claim
 5. 10. A node device connected to a sensor configured to measure a state of a facility, the node device being configured to execute a measurement task, wherein the node device is configured to communicate with a gateway device, and wherein the node device is configured to add node identification information used to identify the node device and task identification information used to identify the measurement task executed by the node device, to measurement data acquired in the measurement task, and send the measurement data to the gateway device.
 11. The node device according to claim 10, wherein the node device is configured to execute another task if a result of one task performed by the node device satisfies a predetermined condition.
 12. The node device according to claim 10, wherein the node device is configured to send an instruction that causes another node device to execute another measurement task, if a result of one task performed by the node device satisfies a predetermined condition.
 13. A gateway device configured to communicate with a plurality of node devices, each of the plurality of node devices being connected to a sensor configured to measure a slate of a facility, and being configured to execute a measurement task, wherein if the gateway device receives from any one of the plurality of node devices, measurement data to which node identification information used to identify the node device and task identification information have been added, the gateway device stores the measurement data to which the node identification information and the task identification information have been added, in a database of an information processing system.
 14. A manufacturing system comprising: a facility configured to manufacture a product; a plurality of node devices, each of the plurality of node devices being connected to a sensor configured to measure a state of the facility, and being configured to execute a measurement task; and a gateway device configured to communicate with the plurality of node devices, wherein each of the plurality of node devices is configured to add node identification information used to identify the node device and task identification information used to identify the measurement task executed by the node device, to measurement data acquired in the measurement task, and send the measurement data to the gateway device.
 15. The manufacturing system according to claim 14, wherein if the gateway device receives the measurement data to which the node identification information and the task identification information have been added, the gateway device stores the measurement data to which the node identification information and the task identification information have been added, in a database.
 16. The manufacturing system according to claim 14, wherein at least one of the plurality of node devices executes another measurement task if a result of one measurement task performed by the at least one of the plurality of node devices satisfies a predetermined condition.
 17. The manufacturing system according to claim 14, wherein at least one of the plurality of node devices sends an instruction that causes another node device to execute another measurement task, if a result of one measurement task performed by the at least one of the plurality of node devices satisfies a predetermined condition.
 18. A method of manufacturing a product, the method comprising: using the manufacturing system according to claim 14; and causing at least one of the plurality of node devices to execute a measurement task while causing the facility to manufacture a product. 